Bringing the On‐Line Control and Optimization of Semibatch Emulsion Copolymerization to the Pilot Plant. Issue 4 (6th June 2017)

• Record Type: Journal Article
• Authors: Zubov, Alexandr; Naeem, Omar; Hauger, Svein Olav; Bouaswaig, Ala; Gjertsen, Fredrik; Singstad, Peter; Hungenberg, Klaus‐Dieter; Kosek, Juraj
• Other Names: Hungenberg Klaus‐Dieter guestEditor.; Reed Wayne F. guestEditor.
• Is Part Of: Macromolecular reaction engineering. Volume 11:Issue 4(2017)
• Page Start: n/a
• Page End: n/a
• Publication Date: 2017-06-06
• Subjects: emulsion copolymerization -- modeling -- on‐line control -- optimization -- semibatch reactor; Polymers -- Periodicals; Polymerization -- Periodicals; Reaction mechanisms (Chemistry) -- Periodicals; Electronic journals; 547.705
• DOI: 10.1002/mren.201700014
• Languages: English
• ISSNs: 1862-832X

Abstract

Abstract : The implementation of model‐based predictive control (MPC) of industrial semibatch emulsion copolymerization is demonstrated. The necessary steps involve the development of process model, its validation and connection with control software, and the realization at pilot‐plant scale. Core of the MPC is the control model which must be fast and robust enough to predict the process trajectory reliably and quickly. Abstract : Due to hardening competition and increased focus on resource efficiency, efforts are made to develop advanced industrial optimization and control systems with the goal to shift the (semi‐)batch production from recipe‐based to a state‐based approach. This study illustrates the steps needed for the implementation of optimization and on‐line control of semibatch emulsion copolymerization involving the development of process model, its validation and connection with control software, and the realization at pilot plant scale. The process model must be fast and robust enough to provide estimation of the process trajectory reliably and quickly. Moreover, in connection with nonlinear model predictive control (NMPC), the model has to be able to learn from the process and to update parameter values in real time, e.g., due to change of reactor jacket heat transfer. The Cybernetica CENIT software is employed for NMPC. The industrial pilot‐scale semibatch emulsion copolymerization of four comonomers (two of them water soluble) is used for the demonstration of NMPC functionality for: (i) reactor temperature control, (ii) minimization of batch time while preserving product quality, and (iii) minimization of batch duration with desired simultaneous shift in product quality.